The present disclosure relates to a process for the recovery of transition metals from batteries comprising treating a transition metal material with a leaching agent to yield a leach which contains dissolved copper impurities, and depositing the dissolved copper impurities as elemental copper on a particulate deposition cathode by electrolysis of an electrolyte containing the leach.

The present disclosure relates to a process for the recovery of transition metals from batteries comprising treating a transition metal material with a leaching agent to yield a leach which contains dissolved salts of nickel and/or cobalt, injecting hydrogen gas in the leach at a temperature above 100° C. and a partial pressure above 5 bar to obtain a nickel and/or cobalt precipitate in elemental form, and separating the obtained nickel and/or cobalt precipitate.

A process for generating a metal sulfate that involves crystallizing a metal sulfate from an aqueous solution to form a crystallized metal sulfate in a mother liquor with uncrystallized metal sulfate remaining in the mother liquor; separating the crystallized metal sulfate from the mother liquor; basifying a portion of the mother liquor to convert the uncrystallized metal sulfate to a basic metal salt; and using the basic metal salt upstream of crystallizing the metal sulfate. So crystallized, the generated metal sulfate may be battery-grade or electroplating-grade.

Provided is a method for inhibiting extractant degradation by a diluent and an extractant input manner, the method including steps of: (a) determining and analyzing the total volume of the DSX solvent when the diluent and the extractant, which are the DSX solvents, are added in the DSX process and identifying the concentration of the extractant; (b) calculating an extractant concentration according to an amount of the diluent to be added based on the analysis value of step (a), and then adding the extractant; (c) determining the ratio between the extractants through analysis after adding the extractants; (d) adding the extractant to be needed when the ratio between extractants is out of the range; and (e) adding the diluent and analyzing the ratio between the extractants.

A method is described for recycling nickel from waste battery material. The method includes providing waste battery material comprising a nickel-containing oxide, reducing the nickel in the waste battery material to the zero oxidation state to provide a reduced waste battery material, reacting the reduced waste battery material with carbon monoxide to form Ni(CO).sub.4, and reacting the Ni(CO).sub.4 with a source of sulfate to form NiSO.sub.4. The NiSO.sub.4 product is useful as a nickel feedstock in various processes which require a nickel source, including processes which prepare new battery materials.

The present disclosure discloses a recycling method for a mixed waste material of lithium nickel manganese cobalt oxide (LNMCO) and lithium iron phosphate (LFP), including: conducting acid-leaching to obtain an acid-leaching liquor with nickel, cobalt, manganese, phosphorus, iron, and lithium; conducting adsorption separation with a resin, washing the resin with sulfuric acid to obtain a mixed solution of nickel sulfate, cobalt sulfate, and manganese sulfate, and subjecting the mixed solution to precipitation to obtain an LNMCO cathode material precursor; and subjecting an obtained solution with phosphorus, iron, and lithium to lithium precipitation to obtain a lithium salt precipitate, and subjecting a post-precipitation solution to concentration and electrospinning to obtain a ferric phosphate/carbon material. The process of the present disclosure can achieve comprehensive recycling of a mixed waste material of LNMCO and LFP and the directed circulation of waste LNMCO and LFP materials.

Battery grade metal sulfate solutions can be prepared directly from electrolytically produced metal objects, such as cathode plates, when these are subjected to an aqueous leaching solution comprising at least one acid leaching agent and a liquid oxidizing agent in a continuous process at elevated temperature and with vigorous mixing. A leaching arrangement comprising a leaching column or reaction vessel is also disclosed.

Disclosed are a method for removing elemental copper from ternary battery waste and its application. The method comprises the following steps: crushing and screening the ternary battery waste to obtain a powder, and then removing iron by magnetic separation to obtain an iron-removed ternary waste; Adding an alkaline solution to the iron-removed ternary waste to perform an aluminum removal reaction, filtering to obtain a filter slag and aluminum-containing wastewater, washing the filter slag with water and drying to obtain a copper-nickel-cobalt-manganese material. Adding an iron salt solution to the copper-nickel-containing material to perform a leaching process, filtering to obtain a leachate and a nickel-cobalt-manganese waste; adding iron powder to the leachate and stirring to perform a reaction, filtering to obtain a copper residue, washing the copper residue with water and drying to obtain a copper-removed liquid and a sponge copper.

Systems and methods for direct recycling and upcycling of spent cathode materials using Flame-Assisted Spray Pyrolysis Technology (FAST). In illustrative embodiments, cathode layers are separated and collected from spent battery cells. The cathode laminate is ground to a powdered form and treated to remove contaminants by sifting into a hot stream of air which heats the powders, burning off contaminants. After cooling and particle collection, the powders may be dispersed into leaching solution to dissolve metal oxides and create an acid metal solution or ground into nano-sized primary particles and mixed with dispersing liquids to form a solution. The solution may be mixed with glycerol and additional metal salts to create a final precursor solution, which may undergo spray pyrolysis followed by drying and calcination to create cathode materials with high consistency and repeatability, or mixed with an alkaline metal salt solution and undergo electrodeposition to recover desired metal salts.

This invention discloses a process and its products for spent lithium-ion batteries treatment, which relates to the field of spent battery treatment technology. This process comprises: fully discharging spent lithium-ion batteries to obtain discharged spent lithium-ion batteries; crushing spent lithium-ion batteries to obtain crushed products of spent lithium-ion batteries; screening crushed products of spent lithium-ion batteries by screens to obtain an overflow and an underflow; sorting the overflow to obtain separator products, plastic products, iron products, copper foil products and aluminum foil products; mechanochemically activating the underflow to obtain activated products; acid leaching the activated products by degradable organic acid to obtain a mixture containing activated products and the organic acid leaching solution; filtering the mixture which contains the activated products and the organic acid leaching solution to obtain graphite as filter residues. Copper mud products and LiNi.sub.0.85Co.sub.0.1Al.sub.0.05O.sub.2 can be obtained after further treatments. This process can effectively recover recyclable resources in spent lithium-ion batteries, and reduce pollution of heavy metals.